Cuffed hose and method of manufacture

ABSTRACT

The present invention is directed towards an improved flexible hose ( 10 ). The hose ( 10 ) is comprised of at least a flexible material ( 28 ) and a reinforcing rod ( 12 ) positioned externally of the flexible material ( 28 ). Terminal ends ( 16, 18 ) define both the flexible material ( 28 ) and the reinforcing rod ( 12 ). At least one terminal end ( 16 ) of the reinforcing rod ( 12 ) is located short of the terminal ends ( 18 ) of the flexible material ( 28 ), so that the non-reinforced end of the flexible material ( 28 ) forms a soft cuff ( 20 ) adapted to be received by a hose fitting. Also disclosed is an improved method of manufacturing the flexible hose ( 10 ).

TECHNICAL FIELD

[0001] The present invention relates to composite hoses, moreparticularly to rubber and plastic hoses comprising an outer helicallyextending reinforcement layer. The hose is constructed to provide foreasier coupling of the hose ends and any desired fittings.

BACKGROUND ART

[0002] Hoses manufactured with outer helical PVC, nylon, or otherplastic-like polymer rod reinforcements are known in the art. Such hosesare also known as drop hoses. Drop hoses are mainly used for thetransfer of various fluids, such as gasoline, petroleum based products,chemicals, food products, etc., in tank truck applications. Drop hoses,and similar corrugated hoses, are made by several differentmanufacturing methods, including those disclosed by U.S. Pat. Nos.4,383,555, 4,471,813, 4,304,266, 4,012,272, and 3,938,929 and disclosedin WO97/24543. The hose ends are generally later coupled with cam andgroove fittings and band clamps.

[0003] Because of the need for a tight fit between a fitting and thehose, the outside diameter of a fitting shank and the inside diameter ofthe hose are almost identical; the shank is usually a bit larger thanthe hose ID. The slightly larger shank OD results in deformation ofthose portions of the hose that are in contact with the shank. Thus acertain force is required to insert the fitting shank into the hose. Theforce required to insert the shank into the hose increases if the hoseis reinforced with a rigid, non-deformable material such as the outerhelical PVC rod. To provide the necessary force or to reduce therequired force, it is known in the art to apply lubricants to hose, toattempt to soft the PVC prior to insertion in the hose, or apply greaterforce to the fitting to ensure a proper insertion. All of these methodsare time and labor consuming and may be detrimental to the hose or thefitting.

[0004] The configuration of the outer corrugations can also make theinsertion of the fittings into the hose bore difficult and make itdifficult to install the band clamps over the plastic spiral wire andachieve a leak proof connection without band distortion and damage tothe hose or fitting. Over the years, aids have been developed toovercome these situations. One such aid is to place a piece of ropebetween the outer corrugations of the cover to achieve a flat surface ateach end of the hose that will make it easier to install the band clampsand prevent distortion. Another aid is the use of a “banding coil.” Abanding coil is a separate spring or coil made out of a plastic-likematerial that is either screwed or wrapped on the cover and fills thecorrugations created by the outer helical wire at each end of the hose.The result achieved by the banding coil is the same as the rope, whichis to end up with a flatter surface to install the band clamps. Anotheraid is the use of a rubber-like sleeve that is slipped over the ends ofthe hose that also attempts to create a flatter surface.

[0005] The present invention of forming a drop hose with soft cuffedends eliminates the known problem in the art and eliminates the use ofexternal aids as described above in coupling this type of hose. Manyother advantages also arise from the present invention, including easierinsertion of the fitting into the hose, reduced labor in coupling thehose, better coupling retention, and a likely reduction of necessaryinventory for hose distributors.

[0006] Corrugated rubber or plastic hose with cuffed ends are disclosedin the following patents. U.S. Pat. No. 4,099,744 discloses a hose endformed flat with no corrugations. U.S. Pat. Nos. 5,398,977, 5,497,810,and EP 330894 disclose a plastic cuff inserted over the corrugations.U.S. Pat. No. 3,640,312, discloses an extruded hose end formed withoutcorrugations and U.S. Pat. Nos. 4,456,034, 4,996,741, 4,996,20,4,295,496, and 4,669,508 all disclose extruded or rubber corrugatedhoses with non-corrugated ends which are internally reinforced byhelically extending wires placed within the extruded or preformedcorrugations. However, the corrugations of these hoses are formed by theextruded layers or by internal helical means, differing from theexternal helical reinforcing means of the conventional drop hoses. It isthe presence of the external helical reinforcing means of the drop hoseswhich has created the need for the external aids and high force requiredto apply fittings to the drop hoses.

[0007] However, in the drop hose of the present invention, thecorrugations are solely formed by the helically extending outerreinforcement, and the base hose material has a constant internaldiameter. While forming cuffs on hose ends is known in the art and theneed for a constant outer diameter at the end of drop hoses to providethe hose with fittings has long been recognized in the art, as evidencedby the numerous types of aids used with conventional drop hose ends,forming a drop hose with cuffed ends in the manner of the presentinvention has not been appreciated or recognized. The present inventionis directed toward a solution of a long felt problem in the art andprovides the many benefits listed above.

SUMMARY OF THE INVENTION

[0008] The present invention is directed towards an improved flexiblehose. The hose is comprised of at least a flexible material and areinforcing rod positioned externally of the flexible material. Terminalends define both the flexible material and the reinforcing rod. At leastone terminal end of the reinforcing rod is located short of the terminalends of the flexible material, so that the non-reinforced end of theflexible material forms a soft cuff adapted to be received by a hosefitting.

[0009] Also disclosed is an improved method of manufacturing theflexible hose of the present invention. The hose is formed by rotating amandrel while feeding a length of material onto the mandrel to build ahose length on the mandrel, feeding a second length of material in theform of a reinforcing rod onto the mandrel to form a helical reinforcingrod on the hose length and curing the hose length. The improvement inthe method of forming the inventive hose is characterized by, prior tofeeding the reinforcing rod onto the mandrel, modifying the hose lengthto create non-adhesive regions.

[0010] Another aspect of manufacturing the inventive hose includesapplying a third material to the hose length to create the non-adhesiveregions.

[0011] Another aspect of manufacturing the inventive hose lies in themethod of applying the reinforcing rod onto the mandrel in the locationsof the non-adhesive region. The speed at which the mandrel rotates asthe reinforcing rod is feed onto the mandrel at the non-adhesive regionsmay be reduced, creating a winding with a greater pitch in thenon-adhesive regions. Or the tension of the reinforcing rod may bereduced as the reinforcing rod is feed onto the mandrel at thenon-adhesive regions.

[0012] Also disclosed is a hose length. The hose length is comprised ofat least one elastomeric layer and a reinforcing rod helically woundexternally of the elastomeric laver. Periodically spaced along the hoselength are non-adhesive regions.

[0013] Another aspect of the disclosed hose length is that thereinforcing rod is not adhered to the elastomeric layer in thenon-adhesive region.

[0014] Another aspect of disclosed hose length lies in the applicationof the reinforcing rod on the elastomeric layer in the locations of thenon-adhesive region. The reinforcing rod may be wound onto theelastomeric layer with a reduced pitch than in the adhesive regions. Orthe tension of the reinforcing rod may be reduced in the non-adhesiveregions.

BRIEF DESCRIPTION OF DRAWINGS

[0015] The invention will be described by way of example and withreference to the accompanying drawings in which:

[0016]FIG. 1 illustrates the inventive hose;

[0017]FIG. 2 is a cross-sectional view of the hose;

[0018]FIG. 3 illustrates the method of manufacturing the inventive hose;

[0019]FIG. 4 illustrates a portion of the hose during manufacture.

DETAILED DESCRIPTION OF THE INVENTION

[0020] The hose 10 of the present invention is illustrated in FIG. 1.The hose 10 has an external reinforcing rod 12 helically wound about aflexible hose base 14. The reinforcing rod 12 has a terminal end 16located a distance from the terminal end 18 of the hose base 14,creating a soft hose cuff 20. The hose 10 has a constant internaldiameter (see FIG. 2), and a minimum and maximum outer diameter createdby the corrugation effect of the reinforcing rod 12 and the flexiblehose base 14 between the windings of the reinforcing rod 12. Since thesoft cuff 20 is an extension of the flexible hose base 14, the cuff 20has an outer diameter corresponding to the minimum outer diameter of thehose 10.

[0021] An exemplary construction of the hose 10 is illustrated in thecross-sectional view of FIG. 2. The flexible hose base 14 is constructedfrom a base layer 22, two reinforcing plies 24, 26 and an outer coverlayer 28. The hose base 14 may be provided with a number of layersdiffering from the illustrated two reinforcing layers 24, 26 and otherrubber layers in addition to the base layer 22. The number and type oflayers comprising the flexible hose base 14 is dependant upon thedesired hose properties as determined by the end use of the hose 10.

[0022] The base layer 22 is constructed of conventional natural orsynthetic thermoelastic vulcanizable material used in the manufacture ofhoses. The reinforcing layers 24, 26 are also formed of conventionalhose reinforcing materials. The cover layer 28 is formed from athermoplastic or thermoelastic vulcanizable material that is capable ofbonding to the base layer 22 and to the reinforcing rod 12 during curingof the hose 10. Examples of typical materials for the base and coverlayers 22, 28 include, but are not limited to, nitrile rubber for thebase layer 22 and a nitrile rubber/PVC blend for the cover layer 28. Thereinforcing rod 12 is formed from a material that is more rigid and/orhas a higher mechanical strength than the cover layer 28, such aspolyvinylchloride. The reinforcing rod 12 may also have an internalreinforcing wire.

[0023] The manufacture of the hose 10 is achieved by spirally windingthe various hose layers 12, 22, 24, 26, 28, onto a mandrel 30, see FIG.3, to produce a hose length 32 which is then cut into short lengths toproduce the inventive soft-cuff hose 10. More details concerning onemethod of manufacturing the hose length 32 are disclosed in U.S. Pat.No. 4,856,720, which is incorporated herein by reference. In this methodof manufacturing, the hose length 32 is built upon a long, straightcircular mandrel 30 that is fixed to rotating drives 34 at each end ofthe mandrel 30. The mandrel 30 is supported by roller bearings 36 atapproximately every fifteen feet. Parallel to the mandrel 30 is atrolley 38 equipped with material applicators 40. The materialapplicators 40 are bobbins provided with the different materials 42 usedin the manufacture of the hose length 32. including rubber, fabric, wirehelix, PVC rod, curing tape, and rope.

[0024] The materials 42 used to construct the hose length 32 are appliedspirally onto the rotating mandrel 30 as the trolley 38 moves parallelto the mandrel 30. The hose length 32 is constructed in this manner byapplying one layer of material 42 over the proceeding layer. Usually thetrolley 38 will apply a layer in a first direction and the next layer inthe opposite direction for symmetry and design purposes. For theillustrated hose length 32, the base rubber layer 22 is first applied tothe rotating mandrel 30, followed by the reinforcing layers 24, 26, andthen the cover layer 28. At this point in the construction of the hoselength 32, a basic softwall rubber hose has been constructed on themandrel.

[0025] To transform the softwall rubber hose length 32 into thehelically reinforced, soft cuffed hose 10 of the present invention thefollowing further steps are taken. At pre-selected regions 46 along thesoftwall rubber hose length 32, a material 44 is applied to render thepre-selected region non-adhesive to further layers applied to the hoselength 32 in the pre-selected region. The pre-selected positions 46along the hose length 32 are at locations corresponding to the lengthsof the individual hoses 10 to be produced. For example, if twenty foothoses 10 (including the cuffed ends) with six inch cuffs 20 at eachterminal end are desired, a pre-selected non-adhesive region 46 isprepared along the hose length 32 for a length of twelve inches everynineteen feet. So for the entire mandrel length, the first six inches ofthe hose length 32 is rendered non-adhesive and then the trolley 38,applying a non-adhesive material 44, is moved nineteen feet furtheralong the mandrel 30 from the position of the first non-adhesive region46. The non-adhesive material 44 is then applied to the softwall rubberhose length 32 for a length of twelve inches to produce two six inchcuffs 20. The steps of moving the trolley 38 nineteen feet and applyingtwelve inches of non-adhesive material 44 is repeated along the lengthof the mandrel 30. The non-adhesive material 44 may be formed from anynon-adhesive material that prohibits the outer rubber layer 28 fromcuring to the reinforcing rod 12. Such materials include, but are notlimited to, nylon tape, film, or sheets, polyester tape, film or sheets,pre-cured rubber tape, film, or sheets, metallic film or sheets, Teflonfilm or sheets, or a liquid non-adhesion material.

[0026] After the non-adhesive material 44 is applied in the pre-selectedpositions, using the trolley 38, the reinforcing rod 12 is applied tothe rotating mandrel 30 and onto the softwall rubber hose length 32. Thereinforcing rod 12 is applied with a constant pitch except over thepre-selected region 46 where the non-adhesive material 44 has beenapplied, see FIG. 4. As the trolley 38 moves past the pre-selectedregions 46 where the non-adhesive material 44 is applied, the speed atwhich the mandrel 30 rotates is reduced, while the trolley speed ismaintained, thus increasing the pitch at which the rod 12 is applied tothe mandrel 30. As illustrated, the hose length 32 on the mandrel 40 hasa variably pitched reinforcing rod 12.

[0027] After the variably pitched reinforcing rod 12 has been applied, arope 48 is inserted in the spaces formed between the windings of the rod12. The rope 48 is applied in the same manner as the reinforcing rod 12,with an increased pitch at the pre-selected areas 46 where a soft cuff20 is to be formed on the finished hose 10. The diameter of the rope 48is sized to maintain the desired pitching of the reinforcing rod 12 onthe hose length 32. The rope 48 also acts as a mold to hold the hoselayers 22, 24, 26, 28 and the rod 12 in place during the curing of thehose length 32. The rope 48 selected may be a conventional braided ropeor a smooth rope; any conventional non-adhesive, flexible cord-typematerial may be used.

[0028] The hose length 32 is cured to vulcanize the layers 12, 22, 24,26, 28 and create adhesion between the various layers 12, 22, 24, 26,28, including between the reinforcing rod 12 and the hose cover layer28. The rod 12 adheres to the cover layer 28 along the hose length 32,except where the non-adhesive material 44 has been applied. After thehose length 32 has been cured, the rope 48 is removed. After beingremoved from the mandrel 30, the hose length 32 is then cut into thedesired final hose lengths. Preferably, the cuts are centered in thepre-selected regions 46 to produce two soft cuffs 20. The cuts may alsobe at one of the edges of the pre-selected region 46 if it is desired toform a hose 10 with only a single cuffed end 30. The portion of thereinforcing rod 12 that is not bonded to the outer cover layer 28 due tothe presence of the nonadhesive material 44 is also removed. As a finalstep, if required, the non-adhesive material 44 is removed from the hosecuffs 20.

[0029] Due to the curing of the hose length 32 with the rope 48 beingwound between the pitched helical windings of the reinforcing rod 12,and the tension force used to wind the rope 48 onto the mandrel 30, theflexible hose base 14 creates an indented imprint between the windingsof the rod 12. The imprint from the rope 48 also extends into the softcuff 20, creating a slight indent 50 in the soft cuff 30. The imprintindent 50 in the cuff 30 does not adversely affect the seal needed inapplying a fitting to the hose cuff 30. If the rope 48 has a braided ortextured pattern, then the indented imprint will be also have a braidedor textured pattern.

[0030] As noted above, the hose 10 is manufactured by spirally windingthe hose layers 12, 22, 24, 26, 28, onto a mandrel 30 to produce a hoselength 32 which is then cut into short lengths with at least one softcuffed end 30. The hose layers 12, 12, 24, 26, 28 may be applied to themandrel 30 by means other than the illustrated traveling trolley 38 andmaterial applicator 40. The layers 12, 22, 24, 26, 28 may be applied bymoving a rotating mandrel 30 past a stationary material applicator 40.The layers 12, 22, 24, 26, 28 may also be applied by helicallyhandwinding the material 42 onto either a rotating or stationary mandrel30.

[0031] Additionally, after the pre-selected region 46 has been modifiedto render that portion of the hose length 32 non-adhesive, thereinforcing rod 12 and supporting rope 48 may be applied by methodsother than varying the pitch of the rod 12 and the rope 48. Thereinforcing rod 12 may be applied at a constant pitch for the entirehose length 32, but with a reduced tension in the pre-selectednon-adhesive regions 46. The rope 48, likewise, would then be applied ata constant pitch but with reduced tension in the pre-selected regions.The reduced tension of the rod 12 and rope 48 prevent the creation ofmultiple indents in the created soft cuff 20.

[0032] Since the inventive hose 10 has a terminal end 18 defined by asubstantially constant inside and outside diameter for a defined length,it is easier to install any desired fittings to the cuffed hose endwithout the difficulties experienced with non-cuffed hoses and withoutneeding to use known fitting aids as previously discussed.

What is claimed is:
 1. An improved flexible hose (10) comprising aflexible material (14) and a reinforcing rod (12) positioned externallyof the flexible material (14), the flexible material (14) being formedwith terminal ends (18), the improvement being characterized by: thereinforcing rod (12) having at least one terminal end (16) being locatedshort of the terminal ends (18) of the flexible material (14), theflexible material (14) thus becoming a soft cuff (20) adapted to bereceived by a hose fitting.
 2. An improved flexible hose (10) inaccordance with claim 1, wherein the hose (10) is further characterizedby an imprinted indent (50) extending through the soft cuff (20).
 3. Animproved flexible hose (10) in accordance with claim 2, wherein thereinforcing rod (12) is wound at a pitch externally of the flexiblematerial (14) and the indent (50) is wound at a pitch greater than thepitch of the reinforcing rod (12).
 4. An improved method ofmanufacturing a hose (10) comprising a) rotating a mandrel (30) b)feeding a length of material (42) onto the mandrel (30) as the mandrel(30) rotates, to build a hose length (32) on the mandrel (30). c)feeding a second length of material in the form of a reinforcing rod(12) onto the mandrel (30) as the mandrel (30) rotates to form a helicalreinforcing rod (12) on the hose length (32), and d) curing the hoselength (32), the improvement being characterized by: prior to feedingthe reinforcing rod (12) onto the mandrel (30), modifying the hoselength (32) to create non-adhesive regions (46).
 5. An improved methodof manufacturing a hose (10) in accordance with claim 4, the methodbeing further characterized by applying a third material (44) to thehose length (32) to create the non-adhesive regions (46).
 6. An improvedmethod of manufacturing a hose (10) in accordance with claim 4, themethod being further characterized by cutting the hose length (32) inthe non-adhesive regions (46).
 7. An improved method of manufacturing ahose (10) in accordance with claim 4, the method being furthercharacterized by varying the speed at which the mandrel (30) rotates asthe reinforcing rod (12) is feed onto the mandrel (30) at thenon-adhesive regions (46).
 8. An improved method of manufacturing a hose(10) in accordance with claim 4, the method being further characterizedby reducing the winding tension of the reinforcing rod (12) as thereinforcing rod (12) is feed onto the mandrel (30) at the non-adhesiveregions (46).
 9. An improved flexible hose (10) made by any of themethods recited in claims 4-8.
 10. A hose length (32) comprising atleast one elastomeric layer (22 or 28) and a reinforcing rod (12)helically wound externally of the elastomeric layer (22), theimprovement being characterized by: non-adhesive regions (46)periodically spaced along the hose length (32).
 11. A hose length (32)in accordance with claim 10, the hose length (32) being furthercharacterized by the reinforcing rod (12) not being adhered to the atleast one elastomeric layer (22 or 28) in the non-adhesive regions (46).13. A hose length (32) in accordance with claim 10, the hose length (32)being further characterized by a rope (48) being wound adjacent to thereinforcing rod (12).
 14. A hose length (32) in accordance with claim10, the hose length being further characterized by the reinforcing rod(12) being wound at a greater pitch length in non-adhesive regions (46).15. A hose length (32) in accordance with claim 10, the hose lengthbeing further characterized by the reinforcing rod (12) being wound at alesser winding tension in the non-adhesive regions (46).